EN - english Instructions for installation and operation Measurement accessories METPOINT OCV for the measurement in systems up to 40 bar
Dear customer, Thank you for deciding in favour of the METPOINT OCV measuring device with sampling probe. Please read these installation- and operating instructions carefully before mounting and starting up the METPOINT OCV measuring device, and follow our directions. Perfect functioning of the METPOINT OCV, and thus exact measurement and monitoring of the residual oil content in compressed air, can only be guaranteed when the provisions and notes stipulated here are strictly adhered to. These instructions for installation and operation are a supplement to the installation and operating instructions METPOINT OCV for the installation and operation of the measurement accessories to be applied in systems with an operating pressure of 40 bar. The installation and operating instructions of the integrated components are not substituted by these, and they shall still be applied in their entirety. They should always be available during the operation of METPOINT OCV in systems with an operating pressure of 40 bar. 2 Measurement accessories METPOINT OCV 40 bar
Contents 1 Contents 1 Contents... 3 2 Operating conditions... 4 2.1 Operating conditions METPOINT OCV... 4 2.2 Operating conditions ball valve 3/8 for METPOINT OCV... 4 2.3 Operating conditions pressure reducer for METPOINT OCV... 4 3 General advice... 5 4 Safety instructions... 6 4.1 Safety labelling... 6 4.2 Signal words in accordance with ANSI... 6 4.3 General safety instructions... 7 4.4 Special advice for plants under pressure in accordance with the 97/23/EC Pressure Equipment Directive... 8 4.5 Special safety instructions... 9 5 Field of application and proper use of the METPOINT OCV 40 bar measurement accessories 10 6 Technical data... 11 7 Transport and set-up... 12 8 Operating principle of the METPOINT OCV 40 bar... 13 9 Description structure and components... 14 10 Details pressure reducer... 15 11 Installation... 16 11.1 Mechanical installation... 16 11.2 Electrical installation / connection to the electric mains... 16 12 Start-up... 16 12.1 Initial start-up... 16 12.2 Restart... 16 13 Removal from service... 17 14 Maintenance... 18 14.1 Care... 18 14.2 Calibration... 18 15 Appendix... 19 Measurement accessories METPOINT OCV 40 bar 3
Operating conditions 2 Operating conditions 2.1 Operating conditions METPOINT OCV Max. permissible operating overpressure PS: 16 bar g Working pressure compressed air: 7 bar g Min. / max. permissible operating temperature of the sensor unit: +5 C / +55 C Min. / max. permissible operating temperature of the evaluation unit: +5 C / +50 C Min./max. ambient temperature: +5 C / +45 C Supply voltage: 230 VAC 50 Hz See also the separate instructions for installation and operation of the METPOINT OCV. 2.2 Operating conditions ball valve 3/8 for METPOINT OCV Max. permissible operating overpressure PS: Working pressure compressed air: Min. / max. permissible operating temperature: Min./max. ambient temperature: 40 bar g 38 bar g -30 C / +60 C +5 C / +45 C 2.3 Operating conditions pressure reducer for METPOINT OCV Max. permissible operating overpressure PS: Max. inlet pressure compressed air: Max. outlet pressure compressed air: Min. / max. permissible operating temperature: Min./max. ambient temperature: 40 bar g 40 bar g 10 bar g -30 C / +60 C +5 C / +45 C See also Chapter "Details pressure reducer", page 15 and Chapter "Appendix" (pressure governor), page 19. 4 Measurement accessories METPOINT OCV 40 bar
General advice 3 General advice Check, prior to reading the operating instructions, whether or not these instructions correspond to the device. Read these installation and operating instructions carefully prior to any intervention regarding the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar. The operating instructions must be accessible at all times at the place of application of the device. To ensure safe operation, the device must only be operated and maintained in accordance with the indications in the operating instructions. In addition, the national and operational statutory provisions and safety regulations, as well as the accident prevention regulations required for the respective case of application, need to be observed during employment. This applies accordingly when accessories are used. Non-observance of the installation and operating instructions involves risks for persons and systems. System performance tests, installation, setting and service measures must only be carried out by authorised skilled personnel. In the event of improper use of the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar, or in the event of non-observance of these instructions, warranty and liability claims are excluded. This symbol stands for actions which can also be implemented by the operators, provided that they are skilled and authorised accordingly. Measurement accessories METPOINT OCV 40 bar 5
Safety instructions 4 Safety instructions In addition to these operating instructions, it is imperative to adhere to the relevant accident prevention regulations, the generally accepted safety rules, the EU directives and country-specific standards and provisions. 4.1 Safety labelling Safety instructions whose non-observance represents a threat to life and physical condition or can lead to property damage are labelled in accordance with DIN 4844 and ANSI Z535. Safety pictograms in accordance with DIN 4844 General danger symbol Compressed gas Note Observe operating instructions Disconnect from voltage 4.2 Signal words in accordance with ANSI Danger! Warning! Caution! Notice! Important! Imminent hazard Serious injury or death Potential hazard Serious injury or death Imminent hazard Injury or property damage Potential hazard Injury or property damage Additional advice, info, hints No danger 6 Measurement accessories METPOINT OCV 40 bar
Safety instructions 4.3 General safety instructions DANGER! Compressed gas! Risk of serious injury or death through contact with quickly or suddenly escaping compressed gas or through bursting plant components. It is the obligation of the operator to ensure that the connected pressure generator is protected against the exceeding of the maximum operating overpressure and of the temperature limits at the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar. Make sure that the system is pressureless prior to integrating the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar into the compressed gas system! Any installation works must only be carried out on the pressureless system. Only use fittings and connecting elements that are approved for this application. It is of vital importance to observe the specifications of the respective manufacturer. Unpressurise the plant prior to any maintenance or repair works! Check all connections prior to the initial start-up and retighten them if necessary. Do not exceed the max. permissible operating pressure (see type plate). The max. permissible operating overpressure is specified on the type plate and in the technical data (see "Technical data" section). Sudden impact through pressure build-up can cause damage and escape of compressed gas. Avoid a sudden pressure build-up by operating the valves slowly. Maintenance, inspection and installation works must be carried out by authorised and skilled personnel only. Prior to undertaking any measures on the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar, the skilled personnel shall read up on the device by carefully studying the operating instructions. The operator is responsible for the adherence to these provisions. The respective directives in force apply to the qualification and expertise of the skilled personnel. Never make structural modifications to the plant! Use genuine spare parts and accessories only! The general safety and accident prevention regulations apply! DANGER! Supply voltage! The operation and maintenance of electrically-powered machines and devices must only be undertaken by correspondingly qualified and authorised personnel. Prior to carrying out service measures, no matter which type, the following notes must be considered: Make sure that no parts of the system are energised and that the METPOINT OCV cannot be connected with the electric supply mains during service measures. WARNING! Unauthorised interventions! Any modification of the components that has not been checked and approved by the manufacturer is potentially dangerous and will void any warranty and liability on the manufacturer's part. Measurement accessories METPOINT OCV 40 bar 7
Safety instructions In the event of fire, do not use water to extinguish it (neither in the vicinity of the system nor directed directly at the system). 4.4 Special advice for plants under pressure in accordance with the 97/23/EC Pressure Equipment Directive The proper use of the measuring device is the basic requirement for safe operation. Therefore, the user must proceed as follows: The METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar must only be employed within the pressure and temperature range limits indicated by the manufacturer on the type plate. No welding measures must be undertaken at the housing parts of the devices. The maximum operating pressure indicated by the manufacturer on the type plate must not be exceeded. It is the user's responsibility to install the appropriate safety and control devices. The documents related to the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar (manual, operating instructions, manufacturer's declaration etc.) must be kept safe for future reference. No objects whatsoever must be installed at or placed on the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar and the connecting lines. DANGER! High pressure! Risk of serious injury or death through contact with quickly or suddenly escaping compressed air or through bursting plant components. Never make structural modifications to the plant! Use genuine spare parts and accessories only! WARNING! Unauthorised intervention! Unauthorised interventions may endanger persons and plants and lead to malfunction. Unauthorised interventions, modification and abuse of the pressure devices are prohibited. User of the devices must observe the local and national pressure equipment regulations in the country of installation. 8 Measurement accessories METPOINT OCV 40 bar
Safety instructions 4.5 Special safety instructions IMPORTANT! Compressed air! Exceeding the maximum pressure can lead to damaging the plant. Observe the indications regarding the maximum pressure on the type plate! IMPORTANT! Operational reliability at risk! Incorrect installation can compromise the operational reliability and affect service measures. Do not exceed the permissible volume flow and working pressure! Do not operate below the working pressure! NOTE! Service measures! Any service measures on the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar must only be carried out on the de-activated, pressureless and de-energised METPOINT OCV. Measurement accessories METPOINT OCV 40 bar 9
Field of application and proper use of the METPOINT OCV 40 bar measurement accessories 5 Field of application and proper use of the METPOINT OCV 40 bar measurement accessories The METPOINT OCV measurement accessories serve to expand the operating pressure range of the METPOINT OCV to 40 bar. With this, the stationary measurement and monitoring of the vaporous and gaseous residual oil content of the compressed air (ISO 8573:2001) in systems with an operating pressure of40 bar is possible. Any other use is considered improper. The manufacturer and the marketer shall not be liable for the consequences of improper use; the user and operator alone is responsible for all risks that may arise. The proper employment and use of the METPOINT OCV according to directions requires the exact compliance with the installation instructions, in particular in respect of: The place of installation, installation conditions The voltage supply and frequency Pressure, temperature and humidity of the inlet air Ambient temperature The measuring device is supplied as accepted in the factory. The user only needs to establish the connections with the supply mains and interconnect the components, which is described in the following chapters. WARNING! Employment for the prevention of dangerous conditions! A device of the METPOINT OCV series must not be employed as the sole means of preventing dangerous conditions at machines and plants. Machines and plants must be constructed in such a manner that defective conditions do not lead to a dangerous situation for persons or plants. WARNING! Improper use! The METPOINT OCV measuring devices and the accessories offer state-of-the-art technology and are operationally safe. Residual risks may emanate from the measuring device and the accessories when improperly installed, employed, or operated by untrained personnel. The METPOINT OCV measuring devices and their accessories must only be used by qualified and authorised personnel and exclusively in accordance with the technical data. 10 Measurement accessories METPOINT OCV 40 bar
Technical data 6 Technical data Name Measurement accessories METPOINT OCV for the measurement in systems with an operating pressure of up to 40 bar Manufacturer BEKO TECHNOLOGIES GMBH Germany, 41468 Neuss, Im Taubental 7 Medium Compressed air, free from aggressive, corrosive, caustic, toxic, flammable, and fire-accelerating constituents Connection sensor unit G 3/8 internal thread Connection measuring probe 3/8 external thread Connection ball valve G 3/8 internal thread Connection pressure reducer ¼ NPT internal thread Max. permissible operating overpressure Operating overpressure METPOINT OCV METPOINT OCV 16 bar(g) Ball valve for METPOINT OCV 40 bar(g) Pressure reducer for METPOINT OCV 40 bar(g) 7 bar(g) Operating overpressure ball valve 38 bar(g) Operating overpressure pressure reducer Primary pressure 38 bar(g) Secondary pressure 7 bar(g) Min./max. permissible operating temperature +5 C / +50 C Min./max. ambient temperature +5 C / +45 C Supply voltage METPOINT OCV 230 V AC 50 Hz Measurement accessories METPOINT OCV 40 bar 11
Transport and set-up 7 Transport and set-up IMPORTANT! Danger through damaged components! Under no circumstances should you start up damaged components. Defective components can impair the operational reliability and cause further damage. The function and service life of the METPOINT OCV in the version for the measurement in systems with an operating pressure of 40 bar depends on the conditions at the place of installation. This place must meet the following requirements: 1. Weather-proof and frost-free installation within a building. 2. The ambient temperature must not drop below or exceed the indications on the type plate. 3. The installation conditions in the separate installation and operating instructions need to be observed and followed. 12 Measurement accessories METPOINT OCV 40 bar
Operating principle of the METPOINT OCV 40 bar 8 Operating principle of the METPOINT OCV 40 bar The METPOINT OCV in the version for an operating pressure of 40 bar was developed for the detection of vaporous and gaseous hydrocarbons in compressed air that is free from aggressive, caustic, toxic, flammable, and fire-accelerating constituents. To determine the residual oil content in systems with an operating pressure of up to 40 bar(g), a partial volume flow can be taken from the system, and the system pressure reduced to 7 bar(g). With the reduced operating pressure, the medium flows through the METPOINT OCV. The measuring probe of the METPOINT OCV is integrated into the pipework system of the customer. The provided ball valve allows for the separation of the METPOINT OCV from the system for maintenance and calibration, without needing to interrupt the compressed-air supply. For the reduction of the operating pressure, a special pressure reducer is installed. For the tubing from the pressure reducer to the METPOINT OCV, a stainless steel pipe Ø 6 x 1 mm is used. The length of the pipework must not exceed 1000 mm. The medium travels at approximately 2 l/min through the METPOINT OCV, which means that the "loss" of compressed air through the measurement in the withdrawn partial flow is negligible. Measurement accessories METPOINT OCV 40 bar 13
Description structure and components 9 Description structure and components 1 - Sensor unit METPOINT OCV (component part METPOINT OCV) 2 - Pressure reducer (measurement accessories) 3 - Connection between the pressure reducer and the ball valve, 1m stainless steel pipe 6 x 1 mm (measurement accessories) 4 - Ball valve 3/8 (measurement accessories) 5 - Sampling probe (component part METPOINT OCV) 14 Measurement accessories METPOINT OCV 40 bar
Details pressure reducer 10 Details pressure reducer The pressure reducer is intended for a maximum primary pressure of 40 bar(g). The secondary pressure is adjusted to 7 bar(g) and can be read at the manometer. No further settings are required on the part of the customer. Measurement accessories METPOINT OCV 40 bar 15
Installation 11 Installation 11.1 Mechanical installation The installation of the METPOINT OCV and of the 3/8 ball valve is carried out in accordance with the specifications in the separate instructions for the installation and operation of the METPOINT OCV. The sensor unit of the METPOINT OCV must be fixed on the part of the customer. The pressure reducer is firmly connected with the inlet into the sensor unit and is fixed in the factory using a holding plate. The connection between the pressure reducer and the ball valve can be flexibly designed. For this purpose, the supplied stainless steel pipe 6 x 1 mm and fittings must be used. The installation can be implemented by the customer, but we recommend having the device installed and started up by our service crew. 11.2 Electrical installation / connection to the electric mains The electrical installation of the METPOINT OCV is carried out in accordance with the specifications in the separate instructions for the installation and operation of the METPOINT OCV. 12 Start-up 12.1 Initial start-up Please proceed according to the description in the separate instructions for installation and operation in order to start up the METPOINT OCV. 12.2 Restart When the METPOINT OCV is started up after a long rest period, please proceed as if you were starting up the device for the first time. Check, above all after service measures or repair, whether or not the components are tubed completely and electrically connected. If this is not the case, carry out the installation properly. Check all of the pipe joints for tightness. 16 Measurement accessories METPOINT OCV 40 bar
Removal from service 13 Removal from service DANGER! High pressure! Risk of serious injury or death through contact with quickly or suddenly escaping compressed air or through bursting plant components. Unpressurise the plant prior to any maintenance or repair works! DANGER! Supply voltage! Contact with non-insulated parts carrying supply voltage involves the risk of an electric shock resulting in injury and death. The connection to the electric mains and the corresponding protective equipment must comply with the legal provisions in force at the place of installation of the METPOINT OCV; the connection and installation must be carried out by correspondingly qualified skilled persons.. NOTE! No repair and maintenance measures under supply voltage! De-energise all connector cables prior to repair or maintenance! The repair and maintenance measures must only be carried out by correspondingly qualified personnel and in accordance with the legal stipulations in force! The general safety regulations in accordance with UVV and VDE shall apply, as well as all relevant safety regulations of the country where the devices are operated. Switch off the compressor. Slowly decompress the system. Disconnect the device from the power supply. Measurement accessories METPOINT OCV 40 bar 17
Maintenance 14 Maintenance The METPOINT OCV in the version for an operating pressure of 40 bar must be subjected to regular inspections and service measures through authorised skilled personnel. For the maintenance of the METPOINT OCV, the specifications in the separate installation and operating instructions apply. Use original BEKO spare parts only. 14.1 Care NOTE! Aggressive cleaning agents and solvents must not be used! 14.2 Calibration For the calibration of the METPOINT operating instructions apply. OCV, the specifications in the separate installation and 18 Measurement accessories METPOINT OCV 40 bar
Appendix 15 Appendix Measurement accessories METPOINT OCV 40 bar 19
Appendix 20 Measurement accessories METPOINT OCV 40 bar
Appendix Measurement accessories METPOINT OCV 40 bar 21
Appendix 22 Measurement accessories METPOINT OCV 40 bar
Appendix Measurement accessories METPOINT OCV 40 bar 23
Subject to technical changes/errors excepted. METPOINT OCV _40 bar_kit_manual_de_2012-02.doc